1998-2003 Suzuki Alto 4 Door Clutch -> Unit Repair Overhaul User Manual
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Clutch -> Unit Repair Overhaul for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

2) Pull out input shaft bearing (1) from flywheel (2) using special
tool and wrench.
Special Tool
(B): 09917-58010 (For 5-speed transmission)
(B): 09921-20200 (For 4-speed transmission)
INSPECTION
Input Shaft Bearing
Check input shaft bearing (1) for smooth rotation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet
head and facing surface. If depression is found to have reached
service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.2 mm (0.05 in.)
Service limit: 0.5 mm (0.02 in.)
Clutch Cover
D Check diaphragm spring (1) for abnormal wear or damage.
D Inspect pressure plate (2) for wear or heat spots.
D If abnormality is found, replace it as assembly. Do not disas-
semble it into diaphragm and pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear or heat
spots. Replace or repair as required.
7C-8 CLUTCH
INSTALLATION
NOTE:
Before assembling, make sure that flywheel surface and pres-
sure plate surface have been cleaned and dried thoroughly.
1) Install flywheel (1) to crankshaft and tighten bolts (2) to specifi-
cation.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 42 N
.
m (4.2 kg-m, 30.5 lb-ft)
2) Using special tool, install a new input shaft bearing to flywheel
(1).
Special Tool
(B): 09925-98210 (For 5-speed transmission)
(B): 09943-88210 (For 4-speed transmission)
3) Aligning clutch disc to flywheel center using special tool, install
clutch cover (1) and bolts. Then tighten bolts to specification.
[4-speed Transmission]
NOTE:
D While tightening clutch cover bolts, compress clutch
disc with special tool by hand so that disc centered.
D For 4-speed manual transmission, be sure to use 2 ream-
er bolts (2) as shown.
Special Tool
(A): 09924-17810
(C): 09923-36330
Tightening Torque
(b): 23 N
.
m (2.3 kg-m, 16.5 lb-ft)
CAUTION:
Tighten cover bolts little by little evenly in diagonal or-
der.
[4-speed & 5-speed Transmissions]
CLUTCH 7C-9
4) Slightly apply grease to input shaft (1), then joint transmission
assembly with engine.
“A”: Grease 99000-25010
“B”: Grease 99000-25210
NOTE:
Turn crankshaft with wrench from front while inserting
transmission input shaft to clutch disc until splines mesh.
7C-10 CLUTCH
CLUTCH RELEASE SYSTEM [FOR 5-SPEED
TRANSMISSION]
REMOVAL
1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft.
3) Unhook return spring (1) using pliers.
4) Drive out No.2 bush using special tool and hammer.
Release shaft seal will also be pushed out.
Special Tool
(A): 09922-46010
5) Remove release shaft (2) and return spring (1).
6) Install tap (M14 1.5)(1) to clutch release shaft No.1 bush.
7) Pull No.1 bush out by using special tools.
Special Tool
(B): 09923-46030
(C): 09930-30102
CLUTCH 7C-11
INSPECTION
Clutch release bearing
Check clutch release bearing (1) for smooth rotation.
If abnormality is found, replace it.
CAUTION:
Do not wash release bearing. Washing may cause grease
leakage and consequential bearing damage.
Clutch release shaft
Check clutch release shaft (1) and its pin for deflection or damage.
If abnormality is found, replace it.
INSTALLATION
1) Drive in a new clutch release shaft No.1 bush (1) using special
tools and then apply grease to bush inside.
Special Tool
(A): 09943-77910
(B): 09923-46030
“A”: Grease 99000-25010
2) Install release shaft with return spring applied to it.
3) Apply grease to clutch release shaft No.2 bush (1) inside and
press-fit it using the same special tool as in removal.
Grease 99000-25010
Special Tool
(C): 09922-46010
4) Apply grease to shaft oil seal (1) and then install it till its upper
end flush with end face of transmission case using special tool.
“A”: Grease 99000-25010
Special Tool
(D): 09925-98221
7C-12 CLUTCH
5) Caulk seal (1) at A using caulking tool and hammer.
A: Caulking
6) Hook return spring (1).
7) Apply grease to release bearing (2) inside and release shaft arm
(3), then set bearing.
“A”: Grease 99000-25010
8) Apply small amount of grease to input shaft spline (4) and front
end as well.
“B”: Grease 99000-25210
9) Set release arm (1) to release shaft aligning their punching
marks (2) and tighten nut (3).
Tightening Torque
(a): 13 N·m (1.3 kg-m, 9.5 lb-ft)
CLUTCH 7C-13

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Clutch
General Description Diagnosis On-Vehicle Service Required Service Materials Special Tools

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